Three-dimensional localization of defects in stay cables using magnetic flux leakage methods

The application of magnetic flux leakage (MFL) methods to the nondestructive evaluation (NDE) of metal parts has been known for several decades. The inspection of large-diameter cables (empty set greater than or equal to 100 mm), such as bridge stay cables, is a new field of application for the MFL method. The large cross-section of the cables requires the generation of strong magnetic fields in order to obtain the induction fields necessary for an accurate inspection of the cables. A new device for the inspection of stay cables has been developed in order to meet the requirements given by the size of the cables. Measurements performed with the developed device on full-scale specimens in the laboratory and first calculations confirm the validity of the MFL approach to the inspection of bridge stay cables. The equipment was used satisfactorily in 2001 for the NDE inspection of the 68 locked coil stay cables (121 mm < empty set < 167 mm) of a bridge in Southeast Asia. For such cables, no exact localization within the cross section was performed. Thus far, an accurate indication of the position of the detected flaws along the length of the cables could be given. A qualitative statement about position and size of the flaws within the cross section of the cable could also be made. Given the large steel cross-section of the cables, no other nondestructive method to confirm the findings could be applied to assess the exact size and position of the detected flaws. The proposed analytical method presented in this paper makes it possible to increase the amount of information that can be extracted from the measured MFL data with regard to the exact location of the detected flaws within a cross section of a stay cable.